Pile fabrics



ck, 4, 195 F. P. GROAT 319,541

PILE FABRICS Original Filed Dec. 28, 1949 INVENTOR. Francis P Great United States Patent PILE FABRICS Francis P. Great, Bloomsburg, Pa., assiguor to The Magee Carpet Company, Bloomsburg, Pa., a corporation of Pennsylvania Original application December 28, 1949, Serial No. 135,444, now Patent No. 2,590,608, dated March 25, 1952. Divided and this application January 21, 1952, Serial No. 267,725

2 Claims. (Cl. 139-406) This invention relates to pile fabrics and method of making the same.

More particularly it relates to loop pile fabrics or loop and tuft pile fabrics wherein some of the rows of loops have loops of different heights. Heretofore, loop pile fabrics have been woven by using a series of knob wires and two or more frames of pile yarns selectively raised over the shanks of the wires which are of uniform height. When the wires are withdrawn, the loops thereon will be raised to the height of the knob which pulls the pile warps so that loops in the preceding row formed from the same warps will be reduced in height an amount equal to the increase in the height of the loops raised by the knob.

By this method the high and low loops are formed by' action of the knob wire and the last loop in each longitudinal series of loops in the same warp will always be a high loop.

In my prior application filed February 2, 1949, Serial Number 74,143, now Patent No. 2,532,903, granted December 5, 1950, I disclosed a pile fabric and method of weaving the same wherein a combination of plain and knob wires with or without cutting wires are used to produce loop pile fabrics or loops and tuft pile fabrics, with the loops in some of the rows being of'diiferent heights. In that method a conventional knob wire is used and the height of the knob corresponds to the height of the plain wire so that the row of loops formed on the knob wire will be raised, when the wire is withdrawn, to the height of the highest loops in the row formed by withdrawal of the plain wire. In other words the withdrawal of the knob wire will reduce the height of some of the loops formed by the plain wire but in so doing the loops on the knob wires will be raised to a uniform height corresponding to the height of the highest loops in the rows of loops of unequal height.

It is an object of the present invention to provide a loop pile fabric or loop and tuft pile fabric having transverse rows of loops of different height and intermediate rows of loops of no greater height than the low loops in the rows of different height loops.

A further object of the invention resides in providing a method of weaving a loop pile fabric or a loop and tuft pile fabric having transverse rows of loops of different heights wherein knob and plain wires arranged in alternation are employed to form rows of loops with all the high loops being formed by the plain wire and with all the loops formed by the knob wire being no higher than the height of those loops in the row of high loops reduced in height by the withdrawal action of the knob wire.

A further object of the invention resides in a method of weaving a loop pile fabric or loop and tuft pile fabric having two or more frames of pile warps selectively raised over plain and knob wires or plain, cutting and knob wires, with the plain and knob wires arranged in alternation wherein the knob wires when withdrawn will raise the loops thereon to a height no greater than the height of the other loops in the same longitudinal series formed from the same pile warp.

Patented Oct. 4, 1955 ice Other objects and advantages of the invention will be apparent during the course of the following description.

In the accompanying drawing forming a part of this specification and in which like numerals are employed to designate like parts throughout the same,

Fig. 1 is an exploded view in perspective of a cut and loop pile fabric being woven in accordance with the invention,

Fig. 2 is a fragmentary warpwise section of the woven fabric,

Fig. 3 is a fragmentary warpwise section showing a series of the wires inserted in the fabric, 9

Fig. 4 is a fragmentary warpwise section of a loop pile fabric, and,

Fig. 5 is a fragmentary warpwise section of the fabric in Fig. 4 showing the wires inserted in the fabric.

In carrying out the method a conventional Jacquard Wilton loom is employed. The fabric to be woven may have two or more frames of pile warps which are selectively raised in accordance with a pattern by the I acquard mechanism over plain, cutting and knob wires if a cut and loop pile fabric is desired or plain and knobwires if an all loop pile fabric is desired. The backing of the fabric is conventional and comprises upper and lower weft threads 5 and 6 bound together by sets of binder warps 7' and 8. Two or more frames of pile warps 9 and 10 extend between the upper and lower weft threads, and stuffer warps 11 as shown in Fig. 2 are disposed beneath the pile warps.

As the pile warps are selectively raised by the Jacquard mechanism the pile forming wires are successively inserted in the fabric. The wires used are plain wires 12, cutting wires 13 and knob wires 14 inserted in the fabric in the order of a plain wire, a cutting wire, a knob wire, a cutting wire, etc. After the insertion of each wire the pile warps are restored to the backing forming rows of loops on each of the wires. The plain wires 12 and cutting wires 13 are of conventional construction with the height of the plain wire being less than the height of the shank of the cutting wire. The knob wire 14 is of special construction having a relative low shank with a raised portion or knob 15 on its end of less height than the height of the plain wire 12. The base of the raised portion or knob is flared outwardly to provide a shoe 16 wider than the shank which serves to maintain the knob in an upright position when inserting and withdrawing the wires. be higher than the loops formed on the plain wires and the loops formed on the plain wires will be higher thanv the height of the knob of the knob wires. After. the desired number of wires have been inserted in the fabric they are successively withdrawn and re-inserted in the usual manner. Withdrawal of a plain Wire produces a row of loops having a height corresponding to the height of the wire. When the cutting wire is withdrawn the loops formed thereon will be cut by the knife blade 17 at the end of the wire forming rows of cut loops or tufts having a height greater than the height of the row of loops formed by the plain wire. When the knob wire is withdrawn the loops formed thereon are increased in height as the loops pass over the knob 15 and if those loops are formed from the same pile warps as loops in the preceding row formed by the plain wire, the loops in the preceding row will be reduced in height a distance corresponding to the increase in height of the loops passing over the knob. The height of the knob 15 is less than the height of the plain wire 12 and when the loops on the knob wire are raised by the knob the amount of yarn borrowed from the loops in the preceding row is such that the loops in the preceding row will not be lowered to a height less than the increased height of the loops raised by the knob. Those pile warps which are raised over the plain Thus the loops formed on the cutting wires will wire and are buried beneath the knob wire will not be pulled by the withdrawal action of the knob wire so that the loops of these pile warps formed on the plain wire will remain high. Thus, the row of loops formed on the plain wire will after withdrawal of the wire and subsequent knob wire have high and low loops in the transverse row and the row of loops formed by the knob wire will be of uniform height of no greater height than the low loops in the rows of different height loops.

In Fig. 1 it will be seen that when the wires are woven in the fabric rows of loops of uniform height are formed on each of the Wires, the loops is on the cutting wire being higher than the loops 19 on the plain wires and the latter being higher than the loops 20 on the knob wires. After withdrawal of the wires, the row of loops 19 on the plain wire areconverted into a row of high and low loops 21 by the action of the knob wire, the loops 18 are converted into tufts 22 by the action of the cutting wire and the loops 20 on the knob wire are increased in height to form a row of loops 23 having a height no greater than the low loops in row 21.

Referring to Fig. 2 it will be seen no pile warp is raised in row one at the right. Warp pile 10 is raised in row two over a cutting wire which upon withdrawal forms a tuft 24. Pile warp 9 is raised in row three over a knob wire which upon withdrawal forms a loop 25 of a height corresponding to the height of the knob. No pile warp is raised in row four. Pile warp 10 is raised in row five over a plain wire which upon withdrawal forms a high loop 26 of greater height than loop 25. Pile warp 9 is raised in row seven over a knob wire and upon withdrawal the loop 27 is raised to the height of the knob. This action of the knob wire exerts no pull on the loop 25 in row three as pile warp 9 is bound in the fabric by four weft threads. Pile warp 9 is raised in row nine over a plain wire and in row eleven over a knob wire. While the plain wire forms a high loop it is subsequently reduced to the height of loop 27 by action of the knob wire in row eleven when the latter is withdrawn. As pile warp 9 is buried beneath four weft threads before being raised again over a knob wire in row fifteen the withdrawal of the wire in this row will have no effect on the loop in row eleven. Thus, it will be seen all the series of loops formed in pile warp 9 will be low loops. The pile warp 10 will form the high loops and tufts as clearly shown.

Fig. 4 illustrates an all loop pile fabric made by inserting Wires 12 and 14, in alternation, during the weaving of the fabric, as shown in Fig. 5. The pile warps 9 and 10 are selectively raised over the wires 12 and 14, as seen in Fig. 5, and upon withdrawal of the wires high and low loops are formed, as shown in Fig. 4. Upon withdrawal of the first wire to the right of Fig. 5, a high loop is formed in warp 10. When the second wire is withdrawn it raises warp 9 to form a loop of less height than the loop formed by withdrawal of the first wire. When the third wire is withdrawn it forms a high loop in warp 9 which is converted to a low loop upon withdrawal of the fourth wire, as the fourth wire is a knob wire and raises the loop thereon so as to pull the warp 9 and borrow yarn from the preceding loop. Thus, the withdrawal of the second, third and fourth wires will form a longitudinal series of low loops in warp 9. The withdrawal of the fifth wire forms a high loop which remains high as warp 9 is not raised over the sixth wire, which is a knob wire, but is raised over the seventh wire which is a plain wire. The warp 10 is raised over the sixth and tenth wires which are knob wires and when the wires are withdrawn they form low loops. By proper selection of the pile warps raised over the series of plain and knob wires weftwise rows of loops of different heights may be formed with intermediate rows of low loops no greater in height than the low loops in the rows of different height loops.

This application is a division of application Serial No. 135,444, filed December 28, 1949, and now Patent No. 2,590,608, granted March 25, 1952.

Having thus described my invention, I claim:

1. A woven pile fabric structure comprising a backing having warp and weft yarns and warp pile yarns woven into the backing, said warp pile yarns having portions raised between adjacent weft yarns to form alternate transverse rows of loops of different heights with some of the loops of relatively low height, other portions of said warp pile yarns being raised between adjacent weft yarns to form intermediate transverse rows of loops of no greater height than the relatively low height loops in said alternate rows, said alternate and intermediate rows having a full complement of loops with the number of low loopsbeing greater than the number of high loops thereby forming areas of low loops which are larger than the areas of high loops.

2. A woven pile fabric structure comprising a backing having warp and weft yarns and warp pile yarns woven into the backing, said warp pile yarns having portions raised between adjacent wefts to form successive weftwise rows of loops, tufts and loops, each alternate row of loops having loops of different heights with some of the loops of relatively low height, each intermediate row of loops having loops of no greater height than the low loops of said alternate rows, said alternate and intermediate rows of loops having a full complement of loops with the number of low loops being greater than the number of high loops thereby forming areas of low loops which are larger than the areas of high loops.

References Cited in the file of this patent UNITED STATES PATENTS 2,141,152 Kaufman Dec. 20, 1938 2,477,249 Harding July 26, 1949 2,553,303 Crawford May 15, 1951 2,575,029 Shuttleworth Nov. 13, 1951 FOREIGN PATENTS 273,409 Great Britain July 6, 1927 

